Re: How do you replace an 1997 Audi A4 quattro fuel pump?
I have a similar problem:
I bought a fuel tank and provided it to Audi to replace in my car. The dealer told me that the bracket that holds the fuel pump in place was broken and thus the whole fuel tank useless. This seemed like a way for them to get me to buy their tank but I am not sure. I looked into it a bit by asking a repair house if the bracket is replaceable and he said yes. Is this the case?
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Re: How do you replace an 1997 Audi A4 quattro fuel pump?
If your talking about the lock ring on the tank there is a special tool but a brass chisel and hammer can be used to turn the ring until its loose enough to unscrew by hand. if this is about removing the pump from the bottom of the tank then there is a special tool for that also but it can be removed by hand you just have to twist it counter-clockwise. and it will be not be easy to turn but i have done it just have a rubber glove on to pad your hand or its going to hurt.
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Most vehicles you have to drop fuel tank. Remove ring on top of tank holding pump assembly in. However you will need special tools to remove assembly from fuel lines. Some vehicles have a access port not sure if you vehicle has one
You will need to replace the fuel sending unit. This is located inside the fuel tank and usually is part of the fuel pump assembly. Try to run your vehicle to a very low fuel level before taking the tank out. Ford is well known for the plastic fuel line connectors that break easy. Pull the white tab out of the line connector and then pull the fuel filter loose. The other lines will require the special tool that raps around the line and when pushed in, will release the round spring that is holding the line on. Have fun.
It is in the gas tank, you have to remove the tank from the car. It needs to be empty or nearly so, and you need to be able to get the car high enough off the ground to have room under it for the tank. If it's not empty you will need a pump to empty it and a container big enough to hold all of the gas. Once it's down, there is a special tool needed to disconnect the fuel lines. Then there is a lock ring that secure th pump assembly to the tank. There is tool for this too but it can be done with a hammer and a screw driver. If you can get this far the rest is self explanatory. Good luck and have fun!
Unfortunately the fuel pump is inside the fuel tank...I have found the best way to remove the pump is to take the entire bed of the truck off..the reason is the straps that hold the fuel tank up have bolts that hold the strap to the frame rail..in my experience..these bolts will snap off , leaving you more work to drill them out an so on..if you do decide to remove the bed there are 8 bolts holding it to the frame...once the bolts are removed ,you want to make sure you unplug the harness for the rear lights and also disconnect the fuel inlet assembly,then you can slide it back just far enough to gain access to the top of the fuel tank..The fuel pump assembly(also called fuel delivery module) will have a large "C" type clip holding it in.Using a screwdriver, you'll need to pop it out from around the diameter of the fuel pump. Then you may need to turn the whole pump a little to remove it...being careful of the float arm that is attached to it. Also, there are tools needed to remove the fuel lines, which should be available for rental from autozone. Be sure to replace the fuel filter as not doing this may void the warranty for the new pump. You will need the special tools for this too.
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.
FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD.
Disconnect the battery.
Relieve the system pressure.
Raise the vehicle.
Drain the fuel tank.
Disconnect the fill pipe hoses.
Loosen fill pipe hose clamps.
Disconnect fill pipe hoses from the fuel tank.
Remove the 4 bolts (2 each side) and remove the skid plate if equipped.
Support the fuel tank.
Remove the bolts and pivot the fuel tank support straps away from the fuel tank.
Disconnect the vapor line fitting at the rear of the fuel tank.
Lower the fuel tank.
To install, reverse the removal procedure
Clean the area around the fuel pump mounting flange.
Using the special tool, remove the fuel tank pump assembly locking retainer ring.
Remove the fuel pump assembly. CAUTION: The fuel pump assembly must be removed and handled carefully to avoid damage to the float arm and filter.
Remove and discard the fuel pump mounting gasket.
Clean the fuel pump mounting flange and the fuel tank mounting surface.
Apply a light coat of Premium Long Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B to the gasket to hold it in position during assembly. Install the fuel pump mounting gasket.
Using the special tool, tighten the fuel pump assembly locking retainer ring.
The in-tank fuel pump module contains the fuel pump and pressure
regulator which adjusts fuel system pressure to approximately 49 psi.
(338kPa). Voltage to the fuel pump is supplied through the fuel pump
relay. The fuel pump is serviced as part of the fuel pump module.
The fuel pump module is installed in the top of the fuel tank and
contains the electric fuel pump, fuel pump reservoir, inlet strainer,
fuel gauge sending unit, fuel supply line and pressure regulator. The
inlet strainer, fuel pressure regulator and level sensor are the only
serviceable items. If the fuel pump requires service, replace the fuel
pump module, using the following procedure:
Remove the fuel filler cap and properly relieve the fuel system pressure.
Disconnect the negative battery cable.
Remove the fuel tank assembly from the vehicle.
Clean the top of the tank to remove any loose dirt.
Using special tool No. 6856 or equivalent, remove the fuel pump locknut by turning it counterclockwise.
Remove the fuel pump and O-ring from the tank. Discard the O-ring.
Thoroughly clean all parts. Wipe the seal area of the tank clean. Place a new O-ring in position on the pump module.
While holding the fuel pump module in place install the locking
ring and tighten to 43 ft. lbs. (58 Nm) using special tool No. 6856 or
equivalent spanner-type tool.
Install the fuel tank assembly.
Reconnect the negative battery cable.
Fill the fuel tank with fuel. Install the fuel filler cap. Turn the ignition switch to the
position to pressurize the system. Check the fuel system for leaks.
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First, you need to make sure you only have a gallon or so left in the tank. Siphon off the gas into an approved container.
Place the car in jack stands for easier access to the gas tank.
You will need to remove the fill hose and vent line from the filler neck.
Place a floor jack under the fuel tank; remove the straps that hold the tank in place. Carefully lower the tank.
You will need to remove the gas lines and vapor lines going to the tank. You may need a special tool for this. You can purchase at a local auto parts store. The tool is placed on the fuel line then pushed into the connector pushing back the fingers that hold the connector together.
After disconnecting lines and wires to tank drop tank all the way to the ground.
If you have the old style, you will need a flat screwdriver and a small hammer to remove the retaining ring that holds the assembly onto the tank. There is three tabs to tap on with the screwdriver and hammer. The new style requires a strap wrench to unscrew the retainer.
With the retaining ring removed you can remove the assembly from the tank.
On top of gas tank where the fuel pump fits in, there a big ring that holds the fuel pump, with a large screw driver and hammer hit the lip on the outer ring counter clock wise, remove ring and pull out on fuel pump assembly.
To replace the fuel pump the fuel tank must be removed, this requires the car be jacked off the ground as far as poss and put on safety stands (always use safety stands!!), the filler neck is then disconnected and then the steel straps tha retain the tank into the car are undone (each has a nut), then the tank is lowered on a jack until u can get to the electrical connectors and the fuel lines and vapor lines, a special tool may be required to remove the fuel pressure and return line, trhe pump assembly is held into the tank by a twist out retainer ring, reverse to install pump and tank back into the car, this is a 2 person job on the ground, be careful, even a small spark from a tool and u are toast.